Selectively applied particulate on nonmetallic substrates

ABSTRACT

The manufacturing of articles relies on the bonding of two or more components to form some forms of the articles, such as a shoe sole bonded with a shoe upper. The bonding may be achieved with a particulate that is applied to a surface of a substrate. The particulate is selectively fused to the substrate with a controlled energy source having multiple energy emitters individually controllable, such as a laser array. The selective application of laser energy allows for specific geometric structures of particulate to be formed on the substrate. The substrate having the fused particulate is mated with another component allowing the fused particulate to bond the first substrate and the second component.

CROSS REFERENCE TO RELATED APPLICATION

This application having attorney docket number NIKE.277590/160215US02CONand entitled “Selectively Applied Particulate on NonmetallicSubstrates,” is a Continuation of co-pending application Ser. No.14/717,674, filed May 20, 2015, which is a continuation-in-part ofapplication Ser. No. 14/248,818, filed Apr. 9, 2014, the entireties ofwhich are incorporated by reference herein.

TECHNICAL FIELD

The aspects hereof relate to an adhesive application technique usingenergy applied to an adhesive particulate to selectively fuse theadhesive particulate to a substrate for eventual use as an adhesive withanother component.

BACKGROUND

Components may be coupled together using a variety of technique. Forexample, an adhesive may be applied to at least one surface of a firstsubstrate (e.g., material) that is intended to be bonded with anothersubstrate. The adhesive may bond the two substrates through physicaland/or chemical bonds. The bonding of two substrates with an adhesivemay be used in any industry. For example, the bonding of two substratesextends into the aviation, automotive, nautical, industrial goods,consumer goods, apparel, and footwear industries, for example.

An exemplary article of footwear, such as a shoe, is described forbackground purposes. A typical shoe comprises an upper and a solestructure. The sole structure, in turn, may comprise a midsole and anoutsole. While a separate midsole and outsole are discussed, it iscontemplated that the sole structure may be formed such that the midsoleand the outsole are merely regions of a commonly formed structure. Forreference purposes, an exemplary shoe may be divided into three generalregions or areas: a forefoot or toe region, a midfoot region, and a heelregion. The shoe also comprises a lateral side and a medial side. Thelateral side generally extends along a lateral side of a user's footwhen in an as-worn configuration. The medial side extends along a medialside of the user's foot when in an as-worn configuration. The lateralside and the medial side are not intended to demarcate specific areas ofthe shoe. Instead, they are intended to represent general areas of theshoe that are used for reference purposes for the following discussion.For example, the medial side and the lateral side may converge near thetoe region at respective sides of a toe box. Similarly, it iscontemplated that the medial side and the lateral side may also convergeat respective sides of Achilles reinforcement proximate the heel region.Therefore, depending on the shoe design and construction, the termsmedial, lateral, toe, heel, and the like generally refer to a proximatelocation and may not be limiting.

The upper portion of an article of footwear is generally secured to thesole structure and defines a cavity for receiving a foot. As mentionedabove, the sole structure may comprise the outsole and the midsole. Theoutsole forms a ground-engaging surface of the sole structure. Themidsole is generally positioned between the upper and the outsole. Theoutsole and/or the midsole may be formed of conventional materials, suchas rubber, leather, or a polymer foam material (polyurethane or ethylenevinyl acetate, for example). The outsole may be integrally formed withthe midsole, or the outsole may be attached to a lower surface of themidsole.

Traditional manufacturing techniques for constructing an article offootwear may rely on a brushing or applying of a liquid adhesive to atop surface of the sole structure (e.g., a top surface of a midsoleportion) and/or a bottom surface of the upper portion. This applicationof adhesive may prove problematic as a sufficient amount of adhesive isneeded to form a sufficient bond between the sole structure and theupper, but too much adhesive can add weight, cost, and potentially bevisually undesirable.

BRIEF SUMMARY

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

Aspects generally relate to particulate that is selectively fused on acomponent, such as an article of footwear. The selectively fusedparticulate may then subsequently be heated for use in bonding thecomponent with another component. For example, a method of applying aparticulate to an article, such as an article of footwear component mayinclude applying a particulate to a portion of the article such that alaser having multiple independently controllable laser energy emittersselectively applies laser energy to the particulate and the article tofuse the particulate and the article selectively. This selectiveapplication of laser energy forms a fused portion of the particulate ina desired geometric pattern that is both effective at bonding componentsand an efficient use of the particulate. After selectively applying thelaser energy, an unfused portion of the applied particulate is removedfrom the article for potential use in a subsequent reapplication ontoanother component. Further, in exemplary aspects, subsequent to removingthe unfused portion of the applied particulate, thermal energy isapplied to the fused particulate for bonding the article with a secondarticle, in an exemplary aspect.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention is described in detail below with reference to theattached drawing figures, wherein:

FIG. 1 depicts an exemplary process where a component for an article offootwear receives a selectively applied laser energy applied thereon toselectively fuse adhesive particulate, in accordance with aspectshereof;

FIG. 2 depicts a cross-sectional view along line 2-2 of FIG. 1, inaccordance with aspects of the present invention;

FIG. 3 depicts an exemplary process that is similar to FIG. 1 where thecomponent for an article of footwear receives a selective laser energyapplied thereon to selectively fuse adhesive particulate, in accordancewith aspects hereof;

FIG. 4 depicts a cross-sectional view along line 4-4 of FIG. 3, inaccordance with aspects hereof;

FIG. 5 depicts a focused view as identified in FIG. 3 as focus region 5,in accordance with aspects hereof;

FIG. 6 depicts a cross-sectional view along line 6-6 of FIG. 5, inaccordance with aspects hereof;

FIG. 7 illustrates a sole component having fused adhesive particulate,which is depicted being activated prior to being mated with an uppercomponent, in accordance with aspects hereof;

FIG. 8 depicts a second example of the upper component and the solecomponent receiving a thermal energy prior to being mated, in accordancewith aspects hereof;

FIG. 9 depicts an alternative method of activating fused adhesiveparticulate for bonding the upper component and the sole component, inaccordance with aspects hereof;

FIG. 10 illustrates a representation of a method for applying anadhesive particulate to an article of footwear component, in accordancewith aspects hereof;

FIG. 11 depicts an exemplary process where a component for an article offootwear receives a selectively applied laser energy applied thereon toselectively fuse adhesive particulate where the laser source and theparticulate distributor move relative to the article, in accordance withaspects hereof;

FIG. 12 depicts an exemplary process where a component for an article offootwear receives a selectively applied laser energy applied thereon toselectively fuse adhesive particulate where the article moves relativeto the laser source and the particulate distributor, in accordance withaspects hereof;

FIG. 13 depicts an exemplary variable laser source, in accordance withaspects hereof;

FIG. 14 depicts an alternative exemplary variable laser source, inaccordance with aspects hereof;

FIG. 15 depicts the variable laser source of FIG. 14 having a firstexemplary variable configuration of laser energy emitters activated anddeactivated, in accordance with aspects hereof; and

FIG. 16 depicts the variable laser source of FIG. 14 having a secondexemplary variable configuration of laser energy emitters activated anddeactivated, in accordance with aspects hereof.

DETAILED DESCRIPTION

Aspects generally relate to adhesive particulate that is selectivelyfused on a substrate, such that the selectively fused adhesiveparticulate may then subsequently be heated for use in bonding thesubstrate with another component. For example, a method of applying anadhesive particulate to a substrate may include applying an adhesiveparticulate to a portion of the article of footwear component, such thata laser array having multiple independently controllable laser energyemitters selectively applies laser energy to the adhesive particulateand the footwear component to fuse the adhesive particulate and thefootwear component selectively. This selective application of laserenergy forms a fused portion of the adhesive particulate in a desiredgeometric pattern that is both effective at bondingcomponents/substrates and an efficient use of the adhesive particulate.After selectively applying the laser energy, an unfused portion of theapplied adhesive particulate is removed from the substrate for potentialuse in a subsequent reapplication onto another component. Further, inexemplary aspects, subsequent to removing the unfused portion of theapplied adhesive particulate, thermal energy is applied to the fusedadhesive particulate for bonding the substrate with a second substrate,in an exemplary aspect.

Aspects also provide for a component of an article of footwear, such asa sole portion. The component comprises a surface, such as a midsolefoot-supporting surface or a midsole sidewall interior surface. Thecomponent is adapted, such as being formed or sized, to form at least aportion of an article of footwear. The component also has an adhesiveparticulate that is in a contacting relationship with the componentsurface. The adhesive particulate forms both a fused region and a secondunfused region. The fused region is a result of selectively appliedlaser energy from a laser source having multiple independentlycontrollable laser energy emitters to the adhesive particulate to fusethe adhesive particulate, which forms the fused region into a specificgeometric pattern on the component surface. The unfused region is aportion of the adhesive particulate to which thermal energy, such as thelaser energy, was not applied sufficiently and therefore did not fuse.The adhesive particulate is fused with the component in the fusedregion, and the adhesive particulate is not fused with the component inthe unfused region. The unfused region is substantially bounded by thefused region on the component surface. The geometric pattern formed bythe fused region substantially forms a perimeter around the unfusedregion allowing for an adequate portion of the surface to have a fusedregion without requiring the entirety of the surface to have the fusedregion, in an exemplary aspect. Stated differently, by selectivelyapplying the laser energy, it is possible to form fused regions thatsurround unfused regions of adhesive particulate.

FIG. 1 depicts an exemplary process 100 where a component 102 for anarticle of footwear receives a selective laser energy 110 appliedthereon to selectively fuse adhesive particulate 202, in accordance withaspects hereof. An article of footwear is an article intended to be wornin connection with a user's foot. Examples of an article of footwearinclude, but are not limited to, boots, shoes, sandals, and the like.Therefore, it is contemplated that aspects provided herein may beapplied to any article of footwear, such as shoes. While an article offootwear is discussed throughout this description, the concepts appliedto article of footwear are exemplary in nature an intended forapplication, in some aspects, outside of footwear manufacturing. Asprovided in the Background, an article of footwear may be formed from anumber of components, such as individual members and assemblies ofmembers. For example, a sole may be a combination of a midsole and anoutsole. Similarly, an upper may be a combination of materials formingthe upper. Therefore, reference to a “component” contemplates bothindividual members as well as assemblies of members. In exemplaryaspects, a component is a midsole portion of an article of footwear.Additionally, in an exemplary aspect, a component is an upper portion ofan article of footwear. With this understanding, FIGS. 1-6 primarilydepict a sole portion for illustrative purposes. However, it iscontemplated that other components, such as an upper, may instead beapplied to the various concepts provided herein and specificallydiscussed with respect to FIGS. 1-6.

The component 102, in this exemplary aspect, is a sole portion having asurface 104. The surface 104 is a foot-supporting surface of thecomponent 102, which is generally described as being generallyhorizontal in relation to the direction of gravitational force. Stateddifferently, the surface 104 is effective to resist the movement ofadhesive particulate as a result of gravitational forces. Thisorientation of surface 104 is in contrast to a non-horizontal surface,such as a midsole sidewall, which will be discussed in FIGS. 7 and 8hereinafter.

A deposition member 106 is illustrated depositing or applying theadhesive particulate 202 onto the surface 104. The deposition member 106is exemplary in nature and any manner of applying the adhesiveparticulate 202 is contemplated. For example, a pneumatic applicator,such as an air-powered sprayer, may apply the adhesive particulate suchthat the adhesive particulate is applied to non-horizontal surfaces in arelatively even manner, in an exemplary aspect. The deposition member106 is intended to illustrate that a deposition member may apply theadhesive particulate 202 as it traverses or otherwise moves relative tothe surface 104, such as in a heel-to-toe direction, a toe-to-heeldirection, a lateral-to-medial direction, a medial-to-lateral direction,or a specific deposition pathway. Further, the deposition member 106 isdepicted as depositing the adhesive particulate 202 across a substantialwidth of the surface 104 in the illustrated example; however, it iscontemplated that the application of the adhesive particulate may be ina more focused or concentrated application, such as will be depicted atFIG. 3 hereinafter.

In an exemplary aspect, it is contemplated that a deposition member,such as an electrostatic powder applicator, may deposit the adhesiveparticulate as charged with an electrostatic charge. This applicationwith a static charge may allow for the non-horizontal application andmaintaining of the adhesive particulate until a subsequent selectivefusing of the adhesive particulate occurs. Further, it is contemplatedthat the static charge reduces an amount of adhesive particulate that isnot maintained on the surface, which leads to manufacturingefficiencies. It is contemplated in an exemplary aspect that aconductive fluid or other material that traditionally forms a groundedreceptor for the electrostatically charged adhesive particulate to beattracted is not applied or otherwise used on the component. Instead,the component, such as a shoe sole portion, may be formed from amaterial that inherently serves as a sufficient ground to attract andmaintain an electrostatically charged adhesive particulate. As such,efficiency in the manufacturing process may be achieved as a separatestep of applying and curing a conducting fluid is not needed to stillachieve sufficient attraction between the appropriately selectedcomponent material (e.g., a foamed material used to form a midsole) andthe electrostatically charged adhesive particulate.

The adhesive particulate provided herein may be a powdered material inan exemplary aspect. For example, it is contemplated that the adhesiveparticulate is comprised of a thermoplastic polyurethane (“TPU”); anethylene vinyl acetate (“EVA”); or a polyolefins material. The adhesiveparticulate may have a mesh size between 4 and 140, 20 and 100, or 70and 90, in exemplary aspects. It is further contemplated that theadhesive particulate has a melting temperature in a range from 50degrees Celsius to 130 degrees Celsius, as that is an operatingtemperature where a selected article of footwear components can receivethe adhesive particulate and be fused, in an exemplary aspect. Moreparticularly, it is contemplated that the melting temperature is 60degrees Celsius to 90 degrees Celsius or 60 degrees Celsius to 80degrees Celsius, in exemplary aspects, to achieve a desiredmanufacturability of concepts provided herein. The selection of anadhesive particulate may be dependent on a desired bonding strength, thecomponent material, and/or a second article of footwear componentmaterial to which the component is to be bonded.

Depending on a material onto which the adhesive is to be bonded, it iscontemplated that various temperature ranges may exist between theadhesive melt temperature and the melting point of the material ontowhich the adhesive is applied. For example, the range between theadhesive melting and the substrate (e.g., component onto which theadhesive is melted) may be less than 160 degrees Celsius. For example,if the substrate is a TPU or a Pebax (i.e., polyether block amidecopolymer) that may have a melting point between 120 degrees Celsius and220 degrees Celsius and the adhesive has a melting temperature between60 and 80 degrees Celsius. Similarly, with the proposed ranges, thedifference, in an exemplary aspect, between melting temperatures of thesubstrate and the adhesive may be as low as 40 degrees Celsius.

Additional substrate materials are contemplated. For example, asubstrate that is a thermoset material that instead of melting at agiven temperature will burn at the given temperature. Examples mayinclude rubber (e.g., thermoset rubber having a sulfur or peroxide curedcrosslink), cross-linked polyoleifin foam (e.g., EVA, butane-based blockcopolymers, octane-based copolymers, mixtures thereof), thermosetpolyurethane foam (e.g., polyester, polyether, polycaproloactone), orthermoset polyurethane elastomers (e.g., polyester, polyether,polycaprolactone). It is further contemplated that each of thesematerials may have a different hardness. For example, the thermosetrubbers and the thermoset polyurethane elastomer may have a hardnessrange of 55 to 75 Shore A. Also, it is contemplated that these substratematerials may have a density range. For example, the cross-linkedpolyolefin may have a density less than 0.35 g/cc and the thermosetpolyurethane foam may have a density less than 0.40 g/cc, in anexemplary aspect. While specific materials are listed and specificcharacteristics are also indicated, it is understood they are exemplaryin nature and not limiting onto the application of aspects providedherein.

Subsequent to the depositing or application of the adhesive particulate202 onto the surface 104 (or any surface), laser energy is selectivelyapplied from a laser 108 to raise the temperature of the adhesiveparticulate to at least a melting temperature of the adhesiveparticulate. The laser 108 may be any type of laser so long as theadhesive particulate, the component, and the frequency/power of thelaser are compatible to result in a fusing of the adhesive particulateand the component. For example, a CO2 laser having a 200 watt rating maybe used with various settings adjusted based on the surface area to becovered, the type of adhesive particulate, and the material forming thecomponent. The speed, power, frequency, fill gap, and wobble may all beadjusted on an exemplary system effective for selectively applying laserenergy. Further, it is contemplated that the laser may be a diode laserproducing energy in the near infrared (“NIR”) spectrum, such as around980 nm. The selection of a laser in the NIR spectrum may allow for theselective and preferential heating of one material over another. Forexample, it is contemplated that a doping agent effective in the NIRspectrum may be included with the adhesive particulate to enhance thethermal energy generation from a given laser energy as perceived by thedoped adhesive particulate. This doping agent may allow for an increasedabsorption of energy and differentiated heating of the component and theadhesive particulate as needed to achieve different melt temperatures toaccomplish fusing/bonding. It is contemplated that the laser may operatein the 800 nm to 2,000 nm frequency range in an exemplary aspect toachieve a desired application of laser energy.

A selective application of laser power may be achieved by specificallypositioning the laser energy 110 (e.g., a laser beam) at a desiredsequence of locations to generate a particular geometric form, such as ahash pattern generally depicted in FIG. 1. The selective application oflaser energy is contrary to the generic application of thermal energy tothe adhesive particulate as a whole, but instead, only certain portionsof the adhesive particulate are exposed to the laser energy. Stateddifferently, the selectively applying laser energy allows for a specificgeometric configuration to be formed as a fused portion within thegreater collection of deposited adhesive particulate. This specificgeometric configuration may optimize the position, quantity, andresulting effect of the adhesive particulate when used as a bondingagent with another component.

An example of selectively applying laser energy may include directingthe laser energy to form a perimeter on a midsole sidewall such thatadhesive particulate is fused on the midsole sidewall to form anappropriate bonding layer near a bite line on an upper. Stateddifferently, it is contemplated that laser energy may be selectivelyapplied to form a perimeter (which does not necessarily extend theentire perimeter of the midsole), such as a 50 millimeter to a 3centimeter wide structure, that is effective to bond the sidewalls of amidsole to an upper. Also contemplated in addition to or in thealternative of the substantial perimeter is a geometric structure formedby selectively applying laser energy to a foot-supporting surface of amidsole. The geometric structure may be formed such that portions ofunfused adhesive particulate are substantially bounded (e.g., surroundedon edges) by fused adhesive particulate. A non-limiting example of abounded geometric configuration includes the depicted hash configurationformed by fused region 206 bounding unfused regions 204, as will bediscussed hereinafter. Other geometric structures are also contemplatedwith the selective application of laser energy, such as organicstructures and repeating patterns. A selectively applied laser energyformed structure is one that is formed based on input and instructionsprovided by a computing system to apply specific laser energy to adefined first location while intentionally avoiding applying laserenergy to a second location on the component.

The selective application of laser energy to the adhesive particulatemay be used to create a number of geometric configurations of fused andunfused adhesive powder areas. For example, it is contemplated that in alinear direction of travel for a laser a first portion on the continuousdirection of travel may be fused with laser energy, a subsequent portionof the linear direction of travel is not fused (e.g., insufficient or nolaser energy is applied), and finally another portion along the samelinear direction of travel is fused by selective application of laserenergy. As such, the selective application of laser energy to theadhesive powder is effective to form regions of fused and unfusedadhesive powder that results in area having adhesive bonded thereto andareas not having adhesive bonded thereto that could not be achievedwithout selective application of laser energy.

The selective application of laser energy may be accomplished by acomputer-controlled motion mechanism mechanically coupled with thelaser, such as an X-Y gantry system. Additionally, it is contemplatedthat selective application of laser energy may be accomplished with amirror galvanometer to effectively direct laser energy at specifiedlocations to achieve a selectively formed fused adhesive particulateregion. Additionally, as depicted in FIGS. 11-16, the laser source maybe comprised of multiple independently controllable laser energyemitters (e.g., multiple laser diodes) that selectively activate anddeactivate each of the multiple laser emitters based on a relativelocation to the substrate. In this example, as one of the laser sourceor the substrate is moved relative to the other, the individual laserenergy emitter's laser energy to selectively apply the laser energy asdetermined locations of the substrate. Regardless of the systemimplemented to specifically direct a laser energy beam, it iscontemplated that a computing system having computer-executableinstructions embodied on a computer-readable media is effective tocontrol the directing mechanism to effectively and selectively fuse theadhesive particulate based on predefined instructions for location,power, speed, wobble, frequency, and other adjustable factors associatedwith the directing mechanism and the laser.

The specific directing of the laser energy along with control over thepower, speed, wobble, and frequency, as contemplated in aspects hereof,provides an ability to selectively apply the hot-melt adhesive that issuperior to alternative methods of applying a hot-melt adhesive. Forexample, some systems may rely on the application of a conductive liquidto a to-be-bonded component and a charged hot-melt adhesive particulatethat is electrostatically drawn to the conductive liquid, which does notenable an efficient opportunity to selectively locate the adhesiveparticulate other than through manipulating the application of aconductive liquid onto the component, which may not allow for specificgeometric structures to be formed from the adhesive particulate nor adesired level of control of the resulting structure to occur. Analternative method of applying a coating on a substrate uses a scanninglaser beam on the surface of the substrate to heat the substrate to asufficient temperature that subsequently melts the hot-melt adhesivewithout having direct interaction of laser energy to the hot-meltadhesive. This example contemplates using the energy from the laser toheat the substrate surface to a sufficient temperature such that when apowdered material is deposited on the substrate, the powdered materialmelts without having direct receipt of laser energy. As such, thesubstrate is heated to a temperature sufficient for the later deposit ofpowder to melt on the substrate from the residual thermal energy. Theheating of the substrate and the lack of selective fusibility of anadhesive particulate fails to provide desired efficiencies needed forthe manufacturing of articles of footwear, such as selectively fusedadhesive particulates to non-metallic substrates, in an exemplaryaspect.

As depicted in FIG. 1, subsequent to the deposition of the adhesiveparticulate, the laser 108 and a selectively directed laser energy 110fuse portions of the adhesive particulate together and with thecomponent 102, in this example. While the directed laser energy 110 isdepicted as a uniform laser application in FIG. 1, in reality the laserenergy 110 may be a focused beam having geometric characteristics (e.g.,size, shape) effective for fusing an appropriate amount of adhesiveparticulate. The resulting fused region 206 extends across one or moresurfaces of the component 102 forming what may eventually be a bondingstructure to bond the component 102 with another component. Because thelaser energy 110 is selectively applied, a portion of the adhesiveparticulate that is not increased in temperature to a meltingtemperature by the laser energy 110 remains in an unfused (e.g.,particulate configuration that has not bonded with neighboring particlesthrough a fusing processes by the elevation to at least a meltingtemperature) configuration, as represented by the unfused regions 204.The unfused regions 204, in this example, are bounded between the fusedregions 206; however, in alternative aspects the unfused regions 204 maybe unbounded by a fused region.

FIG. 2 depicts a cross-sectional view along line 2-2 of FIG. 1, inaccordance with aspects of the present invention. The component 102 isdepicted extending from a heel end toward a tow end. The depositionmember 106 is depicted depositing the adhesive particulate 202 asfree-flowing powder 200 that is deposited by gravity, pressure, or aidedwith electrostatic adhesion as the deposition member 106 traverses thecomponent 102 from the heel end towards the toe end. The thickness ofthe deposited adhesive particulate 202 may be any thickness, such as 1to 3 millimeters in thickness. It is contemplated that the thickness ofdeposited materials may be varied at different locations of thecomponent onto which the material is applied. This difference inthickness may achieve different eventual bonding characteristics of theadhesive particulate to achieve functional advantages.

The laser 108 is projecting laser energy 110 at a particular location onthe component 102 to selectively fuse the adhesive particulate at thatlocation while leaving adhesive particulate in an unfused state atlocations not thermally targeted by the laser energy. As such, fusedregion 206 is depicted within the adhesive particulate similar to theunfused region 204.

As previously discussed, it is contemplated that any geometric structureof fused and unfused adhesive particulate may be formed from theselective application of laser energy that causes the fusing of theadhesive particulate. Further, as will be depicted in FIGS. 3-4 and11-16, it is contemplated that various application techniques,apparatus, and methods may be utilized to selectively fuse and apply theadhesive particulate. As also previously discussed, it is contemplatedthat electrostatic application techniques may be implemented to broadlyapply or to selectively apply the adhesive particulate, in an exemplaryaspect.

FIG. 3 depicts an exemplary process that is similar to FIG. 1 where thecomponent 102 for an article of footwear receives a selective laserenergy 110 applied thereon to selectively fuse free-flowing powder 200,which may also be referred to as adhesive particulate 200, in accordancewith aspects hereof. However, in FIG. 3, the laser 109 is in coordinatedmotion with the deposition member 107 such that the application ofadhesive particulate and selective application of laser energy are anear contemporaneous process, as an alternative option for aspectsprovided herein.

The laser energy 110 is effective to fuse the adhesive particulate 200to the component 102 such that a physical bond and/or chemical bonds areformed there between. This process ensures that an adhesive for bondingtwo or more components together is applied in a proper location and inan optimized geometric structure. As will be discussed hereinafter, thefused adhesive particulate may subsequently be heated or otherwiseactivated to again raise the adhesive particulate to at least a meltingtemperature such that the component onto which the adhesive particulateis fused is functionally bonded with a second component as the adhesiveparticulate solidifies in contact with the first and second components.

FIG. 4 depicts a cross-sectional view along line 4-4 of FIG. 3, inaccordance with aspects hereof. As the adhesive particulate 200 isapplied to the surface 104, laser energy 110 from the laser 109selectively fuses the adhesive particulate together and to the component102 resulting in a desired geometric structure of fused adhesiveparticulate, such as the fused region 206. Because the laser energy isselectively applied, portions of the adhesive particulate remain unfusedfor subsequent removal from the surface 104, such as unfused region 204.

FIG. 5 depicts a focused view as identified in FIG. 3 as focus region 5,in accordance with aspects hereof. In particular, the fused region 206represents a hatch-like geometric structure that is effective to atleast partially surround the unfused region 204. Because the selectiveapplication of laser allows some portions of the adhesive particulate toremain unfused while fusing other regions, the unfused portions may berecycled for later application to a component. Also, because theapplication of the adhesive particulate may be performed with theaddition of agents or other chemicals to provide a temporary bond priorto fusing, those additional agents and/or chemicals do not affect therecyclability of the unfused adhesive particulate.

FIG. 6 depicts a cross-sectional view along line 6-6 of FIG. 5, inaccordance with aspects hereof. In this example, the unfused portions ofthe adhesive particulate have been removed to expose the fused regions206. As such, the adhesive particulate is fused to the component 102such that it forms a coupled geometric structure on the surface 104. Thegeometric structure of fused adhesive particulate may extend above thesurface 104 a defined height, such as 1-3 mm. Further, the width orother geometric configuration may be adjusted to provide varied levelsof adhesive particulate to achieve a desired level of bonding betweencomponents.

As previously provided, the fused adhesive particulate on a firstcomponent, such as a sole, is used for the subsequent bonding of thatcomponent with another component, such as a shoe upper. Therefore, theselective application of laser energy allows for the resulting selectivepositioning of adhesive particulate for eventual use in bonding two ormore components. While the adhesive particulate has been discussed as athermoform type material that can pass through multiple state changes(e.g., solid to liquid to solid to liquid), it may be desired in someaspects to add an agent (e.g., crosslinking agent) to result in athermoset material (e.g., a reactive hot-melt adhesive).

However, if a process is implemented in which the adhesive particulateis heated for purposes of forming the geometric structures prior toapplication of a second component, if the crosslinking agent isintroduced prior to this initial application of laser energy, theadhesive particulate would not be suitable for future heating to achievea bond between the two components. Therefore, in an exemplary aspect, ifa crosslinking agent is to be introduced to a thermoplastic material,the crosslinking agent is introduced after forming the adhesiveparticulate geometric structure. An example of a crosslinking agent mayinclude an encapsulated isophorone diisocyanate (“IPDI”) trimer. Acrosslinking agent may be applied as a water-based dispersion that isdried on the fused adhesive particulate at a temperature that is belowan activation temperature of the agent. Therefore, once the fusedadhesive particulate having been treated with the crosslinking agent isheated above the activation temperature and the melting temperature,crosslinking may commence and heat resistance will be affected to thebonding margins between the component(s) and the adhesive particulate.It is further contemplated that a localized surface variation (e.g.,increased surface area, porosity, roughness) may be introduced to allowfor a more homogeneous distribution of the crosslinking agent (e.g., ahardener) into the fused adhesive particulate.

FIG. 11 depicts another aspect of selectively apply laser energy to asubstrate, in accordance with aspects hereof. As compared with FIGS. 1and 3, a laser source 111 of FIG. 11 is comprised of multiple laserenergy emitters that are individually controllable. For example, FIG. 13depicts a substrate-facing surface of the laser source 111 have multiplelaser energy emitters 113, in accordance with aspects hereof. In thisexample, the laser energy emitters are arranged in a linear fashion;however, it is appreciated that alternative arrangement arecontemplated. For example, FIG. 14 depicts such an alternativearrangement having a higher density of the laser energy emitters 113positioned on the laser source 111. Regardless of the laser energyemitter configuration, each of the laser energy emitters (orcombinations) is individually controllable, such as by a computingdevice, to be activated or deactivated at determined locations relativeto the substrate. For example, FIG. 11 depicts the laser source 112moving relative to the stationary component 102 (i.e., substrate).Alternatively, FIG. 12 depicts the component 102 moving relative to thestationary laser source 111. Irrespective of which element(s) is inmotion, as a particular location of the substrate is positioned relativeto the laser source, one or more laser source emitters are activated toapply laser energy to selectively fuse adhesive particulate in the beampath of laser energy from the activated emitter(s).

An exemplary activation of individual laser energy emitters 113 isdepicted in FIGS. 15 and 16. For example, at a first location relativeto a substrate (e.g., component 102 of FIGS. 11 and 12) a first emitter115 is activated while a second emitter 117 is deactivated, as depictedin FIG. 15. The activated first emitter 115 emits laser energy effectiveto increase a temperature of adhesive particulate and/or a substrate.The deactivated second emitter 117 abstains from providing laser energywithin a beam path of the second emitter 117 such that an substrateand/or adhesive particulate within the potential beam path of the secondemitter 117 does not increase beyond a threshold temperature, such as amelting temperature of a particulate (e.g., adhesive particulate) in thebeam path. Therefore, laser energy may be selectively applied to asubstrate and/or adhesive particulate through the individual control oflaser energy emitters, in accordance with aspects hereof.

Continuing with FIG. 16, when a relative location between the lasersource 111 and a substrate (e.g., component 102 of FIGS. 11 and 12)changes from a position at FIG. 15, the first emitter 115 may bedeactivated and the second emitter 117 is activated. In this example,the substrate and/or particulate in a beam path (e.g., area ofsufficient energy from a given emitter) of the second emitter 117 iselevated in temperature above the threshold level and the substrateand/or particulate in the beam path of the first emitter 115 remainsbelow the threshold level. It is understood that any number of emitters113 may be activated and/or deactivated at any time to accomplish adesired selective application of laser energy, as provided herein.Further, it is contemplated that any number of laser energy emitters maybe incorporated into the laser source 111, in exemplary aspects.

While the use of a laser source having multiple independentlycontrollable laser energy emitters is discussed with respect to acladding technique on a substrate, it is contemplated that the lasersource with the multiple independently controllable laser energyemitters may be implemented in other use situations. For example, in therapid manufacturing and prototyping space, such as additivemanufacturing (e.g., laser sintering), the laser source having multipleindependently controllable laser energy emitters could quickly buildeach layer of the produced part as compared to a traditional energysource. Further, as provided herein, it is contemplated that any laserenergy source may be used as an emitter. For example, diode laseremitters and/or carbon dioxide laser emitters may be implemented inconnection with the laser source 111. As also provided herein, it iscontemplated that a doping element may be introduced and/or used inconnection with the particulate and/or substrate to operate in the nearinfrared (NIR) energy space of the emitters. This NIR energy space mayprovide advantages to the laser source 111 with increased lifeexpectancy of components (e.g., the emitters) and lower cost forcomponents (e.g., emitters), in exemplary aspects.

FIGS. 7-9 illustrate non-limiting examples for a subsequent activationof the fused adhesive particulate for purposes of bonding the component(e.g., shoe sole) with a second component (e.g., shoe upper). Across-section of one or more components (e.g., sole component, adhesiveparticulate layer) is illustrated in FIGS. 7-9 for discussion andexemplary purposes.

A first general technique will be illustrated in FIGS. 7 and 8 in whichit is contemplated that a flash activation, such as by infrared light,may be used to elevate the fused adhesive particulate to a substantialtemperature (e.g., melting temperature). At which point the to-be-bondedcomponents are mated together (e.g., brought together under a sufficientpressure) until the adhesive particulate has recrystallized. A secondcontemplated activation technique, which will be illustrated in FIG. 9hereinafter, contemplates first mating the to-be-bonded components andthen heating the fused adhesive particulate to a sufficient temperatureafter which the pressure is maintained until the temperature can bebrought back down below a crystallization temperature of the adhesiveparticulate.

Turning specifically to FIG. 7, a sole component 704 having fusedadhesive particulate 708 is depicted being activated prior to beingmated with an upper component 702, in accordance with aspects hereof. Aspreviously discussed, it is contemplated that a thermal energy-providingsource may be used to increase the temperature of the fused adhesiveparticulate to a sufficient temperature that the fused adhesiveparticulate may serve as an adhesive between the sole component 704 andthe upper component 702 when mated and maintained with pressure untilthe fused adhesive particulate recrystallizes.

The thermal energy source may be any suitable energy source. In anexemplary aspect, the thermal energy source may be an infrared emitter710 that emits energy in a frequency sufficient to generate thermalenergy at the fused adhesive particulate 708. While a single infraredemitter 710 is depicted, it is understood that any number, combination,type, style, frequency, and the like may be implemented to achieve athermal energy source suitable for aspects provided herein. In thisexample, once the fused adhesive particulate 708 that is on the solecomponent 704 at both a horizontal surface and a sidewall interiorsurface 706 is activated, the sole component 704 and the upper 702 aremated together with forces 712 and/or 711. The components may bemaintained in a compressed relationship for a sufficient time to allowthe fused adhesive particulate to cool and recrystallize forming a bondbetween the sole component 704 and the upper component 702, in anexemplary aspect. Because the components are brought into contact afteractivation of the fused adhesive particulate, the fused adhesiveparticulate may be selected to have a slower recrystallization rateallowing the components to be brought into a mated configuration priorto recrystallizing, in an exemplary aspect.

In the example of FIG. 7, the fused adhesive particulate 708 is onlyprovided on one component, the sole component 704. The upper component702 is free of the fused adhesive particulate prior to being placed in amated configuration. Therefore, the bonding between the sole component704 and the upper component 702 is dependent, in this example, on thefused adhesive particulate 708 of the sole component 704. A bottomsurface 703 of the upper component 702 is brought into contact with thesole component 704 allowing for the fused adhesive particulate 708 tobond the components together, in this example.

Also depicted in this example, the fused adhesive particulate 708extends up the non-horizontal sidewall 706 of the sole 704. Therefore,unlike planar application of powdered materials, aspects contemplatemulti-surface application of the adhesive particulate for fusing. Byproviding the adhesive particulate on the sidewall 706, the solecomponent 704 may be bonded with the upper component up to a bite line,an intersection between the sole sidewall top edge and the upper 702.Therefore, a subsequent adhesive application or additional bondingtechnique may be avoided in the manufacturing of an article of footwearby allowing the fused adhesive particulate to extend across bothhorizontal and non-horizontal surfaces, in exemplary aspects.

FIG. 8 depicts a second example of the upper component 702 and the solecomponent 704 receiving a thermal energy prior to being mated, inaccordance with aspects hereof. In the illustrated example of FIG. 8,the upper component 702 has applied thereon a fused adhesive particulatelayer 705. The fused particulate layer 705 may be formed from a similaradhesive particulate as that forming the fused particulate layer 708applied to the sole component 704. While a single infrared emitter 710is depicted, it is understood that any number, combination, type, style,frequency, and the like may be implemented to achieve a thermal energysource suitable for aspects provided herein.

It is contemplated that multiple thermal energy sources emitting energyat various angles may be implemented to achieve a relatively homogeneousthermal energy generation across the various adhesive particulateportions. It is contemplated that having the fused adhesive particulatelocated on both the upper component 702 and the sole component 704 mayprovide, for some materials forming one or more components, a moreconsistent and complete bond between the components, for example.However, in some aspects having different materials and/or components, asingle application of adhesive particulate may be sufficient to achievea desired bond.

FIG. 9 depicts an alternative method of activating fused adhesiveparticulate for bonding the upper component 702 and the sole component704, in accordance with aspects hereof. In this example, the componentsare mated together under pressure (e.g., pressure 711 and 712) prior tore-activating (e.g., taking to a non-crystalline state) the fusedadhesive particulate. A heat-inducing element, such as a thermallyvariable last 714 may then heat one or more of the components, such asthe upper component 702 in this example. The heating of the componentthen causes the fused adhesive particulate 708 to elevate in temperaturesufficiently to bond the components. The thermally variable last 714 maybe heated using a number of different mechanisms. For example, an energysupply member 716 may provide hot liquid or electrical current forpeltier devices, internal induction devices, resistive heating devices,polymide heating devices, and the like. The heat generated by or in theenergy supply member 716 is sufficient to raise a temperature of theadhesive particulate to a melting temperature allowing for the bondingof the components.

FIG. 10 illustrates a representation of a method 1000 of applying anadhesive particulate to an article of footwear component, in accordancewith aspects hereof. At a block 1002, an adhesive particulate is appliedto a component. As previously discussed, it is contemplated that theparticulate may be deposited by gravity, pressure, electrostaticadhesion, or any suitable means. Unlike some application techniques thatrely on a conducting agent to achieve electrostatic adhesion, aconducting agent may not be applied to the component in an exemplaryaspect. Instead of relying on a conducting agent, the material fromwhich the component is formed serves as a sufficient ground to achieve adesired degree of electrostatic adhesive for the eventual fusingoperation to be performed, in an exemplary aspect. It is furthercontemplated that primer may be applied to the component to achieve astronger bond between the adhesive particulate and the component. Theprimer may be an ultraviolet activated primer that produces a sufficientbonding surface onto which the adhesive particulate may be fused, in anexemplary aspect.

As discussed previously, it is contemplated that the adhesiveparticulate may be a dry or liquid material. In an exemplary aspect, theadhesive particulate is a powdered adhesive, such as TPU, EVA, or apolyoefins material, at least in part. The adhesive particulate may alsobe comprised of a doping agent that allows for varied responses to oneor more energy sources. For example, an infrared doping agent may beincluded in the adhesive particulate that aids in the thermal responseto an infrared energy source. The adhesive particulate may have amelting temperature ranging between 50 and 130 degrees Celsius. It isfurther contemplated that the melting temperature is in a range of 60 to90 degrees Celsius, in an exemplary aspect.

At a block 1004, laser energy is selectively applied to the adhesiveparticulate. The adhesive particulate affected by the laser energy isincreased in temperature sufficiently to fuse and bond with theunderlying component. The sufficient temperature is at or above themelting temperature of the adhesive particulate, in an exemplary aspect.The fused adhesive particulate forms a geometric structure, a fusedregion, that is selected to result in an appropriate quantity of theadhesive particulate at a desired location to achieve a desired bondingbetween two components. For example, it is contemplated that through theselective application of laser energy, a band of fused adhesiveparticulate may extend around an inner sidewall up to near a top edge tosecurely bond the sole to an upper at the bite line. Similarly, afoot-supporting surface of a sole may have a geometric pattern, such asa bounded structure, that provides consistent or relatively uniformdistribution of adhesive particulate without requiring a completesurface covering of the adhesive particulate. In this example, it iscontemplated that a precise application of adhesive particulate may beachieved through the selective application of laser energy, such thatdepending on some component size, style, and shape, a predeterminedamount and coverage of fused adhesive particulate is achieved.

The selective application of laser energy may include applying laserenergy in a first location and omitting laser energy in a secondlocation. The omission may be accomplished by blocking the laser energyor eliminating power to the laser. Regardless, where the laser energy isprovided, a fusing of the adhesive particulate may occur, and where thelaser is not applied, the adhesive particulate remains as a free-flowingparticulate, in an exemplary aspect. Similarly, it is contemplated thata frequency, speed, or power level of the laser may be adjusted to alterwhether the adhesive particulate achieves a melting temperature (e.g.,fuses) or does not melt in a given location.

At a block 1006, unfused adhesive particulate is removed from thecomponent. Unfused adhesive particulate is adhesive particulate that wasnot elevated for a sufficient time to a sufficient temperature to fusewith at least the underlying component. The unfused material may beremoved by gravity, compressed fluids, vacuum, or other removaltechniques. In an exemplary aspect, because a crosslinking agent was notused prior to application of the laser energy, the unfused material maybe recycled for subsequent operations.

At a block 1008, thermal energy is applied to the fused regions of theadhesive particulate. The thermal energy may be provided by an energyemitter, such as an infrared light source, or it may be provided by aconductive member, such as a thermally regulated last, in an exemplaryaspect. This application of thermal energy elevates a temperature of thefused adhesive particulate sufficiently to achieve a melting temperaturestate transition that allows the adhesive particulate to serve as abonding agent between two components. It is also contemplated that acrosslinking agent may be introduced to result in a thermoset materialsuch that a subsequent application of heat is less likely to result in aloss of bond between the two components. In the example having acrosslinking agent included, the temperature may be raised in the rangeof 60 degrees Celsius and 80 degrees Celsius, in an exemplary aspect. Inan example where a crosslinking agent has not been specifically added,the temperature of the adhesive particulate may be raised to atemperature range between 80 degrees Celsius and 110 degrees Celsius, inyet another exemplary aspect. The use of a crosslinking agent may dependon the characteristics of the substrate onto which the adhesiveparticulate is fused. For example, if physical characteristics orchemical characteristics of the substrate are affected by the highertemperature range used in an exemplary heating of a non-crosslinkingadded adhesive particulate, the lower temperature range of the crosslinking laced adhesive particulate may be implemented, for example.

A block 1010 represents an optional step of recycling the unfusedportion of the adhesive particulate for a subsequent application toanother article of footwear component. As previously provided, it iscontemplated that the adhesive particulate is useable in a subsequentoperation as it is a thermoform material that may be brought to amelting temperature to fuse or bond with one or more components. Whilespecific examples in FIG. 10 are directed to articles of footwear, it iscontemplated that the method steps are applicable to other fields,articles, and industries, as provided herein and discussed hereinafter.

While exemplary aspects are provided herein with a focus onimplementation in connection with an article of footwear, it isunderstood that features specifically and the concept generally may beapplied to a variety of implementations. For example, the automotive,aeronautical, light industrial, heavy industrial, electronicmanufacturing, nautical applications, communications, and the like mayall leverage concepts provided herein. As such, it is contemplated thatthe illustrated examples directed to an article of footwear may not belimiting but merely exemplary in nature in some aspects.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

Since many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is to be understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illustrative and not in a limiting sense.

What is claimed is:
 1. A method of applying a particulate to anonmetallic substrate, the method comprising: applying a particulate toa portion of the substrate; selectively applying laser energy from alaser source having multiple independently controllable emitters oflaser energy selectively activated, the selective application of laserenergy is applied to the particulate and the substrate to fuse theparticulate and the substrate selectively, forming a fused particulateportion; and after selectively applying the laser energy, removing anunfused portion of the applied particulate from the substrate.
 2. Themethod of claim 1, further comprising: subsequent to removing theunfused portion of the applied particulate, applying thermal energy tothe fused particulate for bonding the substrate with a second substrate.3. The method of claim 1, wherein applying the particulate uses anelectrostatic applicator that electrostatically charges the particulate.4. The method of claim 3, wherein the particulate is electrostaticallyapplied to the substrate without the use of a conducting agent.
 5. Themethod of claim 1, wherein the particulate is comprised of a powderedadhesive comprised of at least one selected from the following: athermoplastic polyurethane (“TPU”); ethylene vinyl acetate (“EVA”); andpolyolefins.
 6. The method of claim 1, wherein a melting point of theparticulate is within the range of 50 degrees Celsius to 130 degreesCelsius.
 7. The method of claim 1, wherein the particulate is comprisedof an infrared doping agent.
 8. The method of claim 1, whereinselectively applying the laser energy comprises applying the laserenergy to a first portion of the particulate in a location relative tothe substrate where fusion is desired and not applying the laser energyto a second portion of the particulate in a location relative to thesubstrate where fusion is not desired.
 9. The method of claim 1, whereinselectively applying the laser energy comprises varying a level ofenergy applied from a laser at a first location of the substraterelative to a second location of the substrate.
 10. The method of claim1, wherein selectively applying the laser energy comprises directing thelaser energy at a first location of the substrate and intentionallyavoiding application of laser energy at a second location of thesubstrate.
 11. The method of claim 1, wherein selectively applying laserenergy produces a fused particulate perimeter enclosing a non-fusedparticulate area.
 12. The method of claim 1, wherein the laser energy isproduced by a diode laser in at least the near infrared spectrum range.13. The method of claim 2, wherein subsequent to removing the unfusedparticulate, applying a crosslinking material comprising an encapsulatedisocyanate hardener to the fused particulate.
 14. The method of claim 2,wherein the application of thermal energy is, at least in part: producedfrom an infrared energy source; or conducted through the substrate tothe fused particulate.
 15. The method of claim 2, wherein subsequent toapplying thermal energy to the fused particulate, bonding an article offootwear component with the second substrate.
 16. The method of claim15, wherein the second substrate is comprised of a fused particulateportion.
 17. The method of claim 1, wherein the laser source havingmultiple emitters of laser energy selectively activated is comprised of:a first laser emitter activated at a first location relative to thesubstrate and a second laser emitter deactivated at the first location;and the first laser emitter deactivated at a second location relative tothe substrate and the second laser emitter activated at the secondlocation.
 18. The method of claim 1, wherein each of the multipleemitters of laser energy are selectively activated and deactivated basedon a relative location to the substrate.
 19. The method of claim 1further comprising moving the substrate relative to the laser source,wherein the laser source is statically positioned while the substratemoves.
 20. The method of claim 1 further comprising moving the lasersource relative to the substrate, wherein the substrate is staticallypositioned while the laser source moves.